Apparatus and methods for resizing electronic displays

ABSTRACT

Apparatus and methods for resizing COTS AMLCDs or other electronic displays, as well as resized displays made using these apparatus and methods, are provided. The electronic display includes a front plate, a back plate, a perimeter seal spacing the front and back plates apart, and image-generating medium contained in an area between the front and back plates. A target portion of the display may be identified and separated from an excess portion of the display, e.g., by cutting and breaking the plates of the display, thereby creating an exposed edge along the target portion. The plates of the target portion are pressed towards one another, e.g., to stabilize or compress the target portion. An adhesive is applied to the exposed edge, and the pressure is released to draw the adhesive between the plates along the exposed edge.

RELATED APPLICATION DATA

This application is a continuation of co-pending application Ser. No.12/848,931, filed Aug. 2, 2010, issuing as U.S. Pat. No. 8,235,761,which is a continuation of application Ser. No. 11/574,504, filed Feb.28, 2007, now U.S. Pat. No. 7,780,492, which is a national filing under35 U.S.C. §371 from International Application No. PCT/US2004/028563,filed Sep. 2, 2004, the entire disclosures of which are expresslyincorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates generally to electronic displays, and moreparticularly to apparatus and methods for modifying electronic displays,e.g., to customize, resize, and/or ruggedize an original display, and todisplays manufactured using such apparatus and methods.

DEFINITIONS

In this application, COTS is an acronym for “Commercial Off-The-Shelf,”FPD is an acronym for “Flat-Panel Display,” LCD is an acronym for“Liquid Crystal Display,” PDLC is an acronym for “Polymer-DispersedLiquid Crystal,” AMLCD is an acronym for “Active Matrix Liquid CrystalDisplay,” TAB is an acronym for “Tape-Automated-Bonding,” COG is anacronym for “Chip-On-Glass,” UV is an acronym for “ultraviolet,” VLSI isan acronym for “Very Large Scale Integration,” and HDTV is an acronymfor “High-Definition Television.”

BACKGROUND

Electronic displays are commonly used to portray data, e.g., in the formof visual text and/or other images, so the data may be interpretedand/or acted upon. Typically, the operator of equipment associated withthe display will control the equipment based, at least in part, on theinterpretation of the data displayed. A simple example is an airplanepilot who views a control panel display representing surrounding airtraffic, and who then controls the airplane to avoid the traffic.

Typically, the displays and their associated bezels (face plates) andframes (interfacing and supporting hardware) are built to demandingspecifications for durability, reliability, and operating life, e.g.,based upon industry requirements, and the resulting displays may haverelatively complex electrical, chemical, optical, and/or physicalcharacteristics. Each particular application, for example, may requirespecific performance characteristics from the display, such as theability to accommodate or withstand varying conditions of temperature,humidity, radiation, ambient light, shock, vibration, impact, chemicals,salt spray, water and fluid condensation, immersion, or otherenvironmental, electrical, physical, and/or other conditions. Due to thehigh costs associated with such varying and demanding specifications,for any particular application, it is thus economically desirable formanufacturers to produce a common design in high production volume,resulting in COTS displays all having substantially the samecharacteristics and a limited number of physical sizes. The sizes mayvary, but the shapes are generally rectangular with an aspect ratio ofapproximately three to four. For example, common television and computerdisplays have an aspect ratio of approximately three to four, and HDTVdisplays have an aspect ratio of nine to sixteen.

For specialized applications where the market may not be large enoughfor COTS manufacturers to enter, buyers of displays are required to havedisplays custom-built to fit their size and shape requirements, at acost often more than ten times greater than the cost of a COTS displayhaving nearly identical functionality. Alternatively, buyers may chooseto incorporate a COTS display into an existing control panel ordashboard opening, e.g., by physically altering the size and/or shape ofthe control panel opening to match the size and/or shape of the COTSdisplay. For most applications, however, such modifications cannot bemade without disturbing the surrounding instruments, controls, anddisplays already incorporated into the control panel. Such is the case,for example, on an airplane control panel or other vehicle control panelwhere large numbers of instruments and controls are tightly andefficiently packed into a relatively small area. Even if the appropriatemodifications could be made, they are typically cost-prohibitive.

A particular industry where high-cost custom-built displays are used isthe avionics industry, which traditionally used square panel openings tohouse mechanical display devices. To retrofit airplane control panelswith electronic displays, the industry began manufacturing customdisplays at a relatively high cost and relatively low volume compared toCOTS non-square displays that are commercially used in high volumeapplications. In fact, the control panels in newly-built airplanesdesigned to use electronic displays are still often made with squarepanel openings, despite the COTS displays being non-square, in order tomaintain the well-established and familiar control panel configurations.

SUMMARY OF THE INVENTION

The present invention is directed to apparatus and methods for modifyingelectronic displays, e.g., to customize, resize, and/or ruggedize anoriginal display, and to displays manufactured using such apparatus andmethods.

Typically, a COTS AMLCD or other electronic display includes two plates,front and back, that include orthogonal row and column electric leadsdistributed throughout an image-generating medium contained between theplates. The display also includes a perimeter seal holding the platestogether while isolating and protecting the internal image-generatingmedium from the outside environment. The plates are typically glass orplastic, and may have polarizers, filters, image enhancement films,and/or viewing angle enhancement films, e.g., attached to their outersurfaces.

The plates of the display may hold drive electronics on their edgesand/or the drivers may be integral in the display. The row and columnelectric leads transcend the seal to external leads to which the driverelectronics are attached. Typically, the electronic drivers are VLSIcircuits bonded to TAB substrates attached to the display, or directlyattached to the display as COG. In some instances, the VLSI electronicdrivers are made in-situ along the edges of the display.

The present invention involves systems and methods for modifying a COTSdisplay, e.g., by changing the physical size and/or shape of the COTSdisplay to meet the requirements of a target application. This may beaccomplished by cutting the COTS display to reduce its physical sizeand/or shape, and then resealing the display to achieve the desiredperformance. The basic functionality of the COTS display may remainintact, that is, the customized display may have a new size and/orshape, and may have altered electronic drivers, image-generating media,rearranged electronics, additional seals, additional films, etc.Optionally, the resized display may have enhanced functionality.However, the customized display should be able to operate in a targetapplication designed to interface with a display of the same type (e.g.,LCD) as the original (e.g., COTS) display.

When the plates are cut, internal electronics may also be cut, oftenrequiring reestablishment of electrical continuity. Similarly, thedisplay electronics may be removed, reattached, and/or otherwisemodified, and filters, polarizers, and/or other films associated withthe display may be cut, e.g., to conform to the customized display sizeand/or shape. Thus, the opportunity exists to add enhanced functionalityto the display. Optionally, a custom bezel and/or frame may then be usedto house the display, e.g., allowing for additional ruggedization of theentire unit.

To reseal the display, an adhesive is applied along at least the cutedge or edges, e.g., between the plates of the display along the cutedge(s). Optionally, a second seal may be added to minimize penetrationof humidity and other contaminants into the display medium (e.g., liquidcrystal material) inside the display cell. A third seal, e.g., servingas a mask, may also be applied to prevent light, such as that used toback-light LCDs, from passing through the display's outer edges.

Electronic drivers, typically VLSI circuits (bonded to TAB substratesattached to the display, or attached directly to the display as COG) maybe added, repositioned and/or reattached as needed, and the circuitry onthe display plates may be altered to make electrical connection to thenew VLSI circuits. Filters, films, polarizers, etc. may then be cutand/or installed as desired, and additional components such as heaters,optical elements, infrared filters, touch panels, transducers, etc., maybe added to alter and/or enhance durability or functionality of thedisplay.

Finally, the reshaped, resized, and/or otherwise modified display may beplaced in a custom bezel and frame with appropriate ruggedizationcharacteristics. The bezel and frame may be designed to accommodate thenewly sized and/or shaped display in a suitable manner, and/or to allowfor proper mechanical and electrical attachment to the target location,such as an avionics box or display panel. The bezel and frame may alsobe configured for installation such that appropriate lighting, opticalelements, transducers, heaters, infrared filters, touch panels, etc.,associated with the target application operate properly. Thus, the framemay protect the display and interface the display with the targetlocation, such as an avionics box or display panel. Suitable adhesives,sealants, conformal coatings, potting compounds, electrical and thermalconductors, screws, clamps, rivets, connectors, gaskets, etc., may beused as necessary or desired to further ruggedize the unit and installit into its target location. For example, ruggedization may be requiredbefore installing the customized unit into environments for vehicles,ships, submersibles, missiles, aircraft, spacecraft, portable equipment,etc., which tend to be more restrictive and severe than the environmentsfor which COTS displays are designed.

Thus, one aspect of the present invention may involve cutting anelectronic display along desired dimensions, resulting in a targetdisplay portion and an excess display portion, and applying a first sealbetween the plates along an exposed edge of the target display portion,the first seal creating a barrier to prevent the image-generating mediumfrom escaping out of the area between the plates. A second seal and/or athird seal may be added, e.g., for environmental protection and edgelight control respectively. The first seal may also serve thesepurposes.

Another aspect of the invention involves resizing or otherwise modifyingthe associated electronics of a display. For example, the electroniccircuits inside the display and/or peripheral to the display may beresized to the same degree necessary to achieve the desired displaysize.

In accordance with another aspect of the invention, a method is providedfor resizing, customizing, enhancing or otherwise modifying anelectronic display that includes one or more of the followings steps inthis or other orders or sequences: removing excess electronics from thedisplay; cutting one or more circuit boards of the display; removing atleast a portion of polarizers and/or other films, as necessary, from oneor both plates of the display, e.g., along the intended cut line(s);cleaning along the intended cut line(s); scribing the plates along thedesired line(s), e.g., with a glazer's wheel, saw, laser, and the like;breaking the plates to separate a target portion from an excess portion,thereby creating an exposed edge of the target portion; stabilizing thedisplay, e.g., in a fixture to apply sufficient pressure to restore theoriginal distance between the plates and/or prevent the plates fromexpanding; removing liquid crystal (LC) from between the plates alongthe exposed edge, e.g., by wicking, draining, compressing the platestogether to eject LC material, and the like, to create a region foradhesive between the plates; clean the exposed edge; apply adhesivealong the exposed edge; degas the adhesive; cause or allow adhesive togo between the plates, e.g., without significantly changing the distancebetween the plates, clean the adhesive, and cure adhesive.

In yet another aspect of the invention, resized, customized, orotherwise modified electronic displays are provided that include cut orotherwise exposed edges and/or one or more seals along and/or betweenthe plates of the displays, e.g., made using one or more of the methodsdescribed herein. Other aspects and advantages of the present inventionwill be apparent from the detailed description which follows, when readin conjunction with the associated drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a plan view of a typical COTS AMLCD.

FIG. 1B is a cross-sectional view of the COTS AMLCD of FIG. 1A, takenalong line 1B-1B, with column TABs removed from the cross-section forpurposes of clarity.

FIG. 2A is a plan view of a customized display made from the COTS AMLCDshown in FIG. 1A, by cutting along line 2-2 in FIG. 1, and thenresealing a retained portion of the display.

FIG. 2B is a cross-sectional view of the customized display of FIG. 2A,taken along line 2B-2B, with the column TABs removed from thecross-section for purposes of clarity.

FIG. 3 is a cross-sectional view of a fixture including a pair ofpressure plates holding an electronic display between the pressureplates.

FIG. 4A is a perspective view of an apparatus for resizing an electronicdisplay, including a pressure plate tool in its open position with adisplay in place on a first pressure plate of the tool.

FIG. 4B is a perspective view of the apparatus of FIG. 4A, with a secondpressure plate of the pressure plate tool secured to the first pressureplate for holding the display in an orientation for adhesiveapplication.

FIG. 4C is a perspective view of the apparatus of FIGS. 4A and 4B,including a cover disposed over the pressure plate tool for degassingthe display.

FIGS. 5A and 5B are top and side views, respectively, of a firstpressure plate for the pressure plate tool of FIGS. 4A-4C.

FIG. 6 is a flowchart showing an exemplary method for resizing orcustomizing an electronic display.

DETAILED DESCRIPTION

Turning to the drawings, FIGS. 1A and 1B show a typical non-square COTSAMLCD 10, e.g., before resizing and/or other modification as describedherein, but after disassembly from its original bezel, frame, and otherassociated hardware and electronics. For clarity, some of the externalcomponents associated with the display 10 (other than the circuit boards15) are not shown, e.g., that may be bonded or otherwise attached to thedisplay plates 20 f and 20 b. Such external components may be removedbefore or while customizing the display 10, as described elsewhereherein.

The display 10 generally includes a front plate 20 f and a back plate 20b, e.g., made of glass or plastic, such as borosilicate or other hardglass. The plates 20 are held together by a perimeter seal 25, and maybe further secured within a bezel (not shown), which, in turn, may besecured to a frame or other hardware (not shown), e.g., for attachmentto the target location, e.g., in a cockpit panel of an aircraft.Polarizing films 30 f and 30 b, filters (not shown), image enhancementfilms (not shown), retardation films (not shown), viewing angleenhancement films (not shown), and/or other films may exist on the frontand/or back outer surfaces of the plates 20. The original display imagearea 40 defined by the manufacturer of the COTS display 10 is indicatedby dashed perimeter line 45. Dashed line 50 represents the desired rightedge of the display image area 40 after customization, as describedbelow. A light-blocking mask (not shown), e.g., an opaque coating, maybe provided on at least one of the inner surfaces of the plates 20,e.g., covering a perimeter area around the display image area 40, andextending outwardly to a sufficient distance to serve its purpose.Typically, the distance may be up to the edge of the bezel, or to theinner edge 55 of perimeter seal 25, as indicated by arrows 60 in FIG.1A. Without the mask, light escaping from the edge of the display imagearea 40 may distract a person viewing the display 10 and/or otherwiseimpair viewing an image on the display 10.

Row and column electronic drivers 65 r and 65 c respectively are bondedto TAB substrates 70 r and 70 c respectively, which in turn are bondedto the edges of the plates 20, e.g., using electrically-anisotropicadhesives 75 known in the art. In avionics, bent TABs (not shown) may beused to save panel area. In addition or alternatively, the drivers 65may be attached directly to the plates 20 as COGs. The TABs 70 may bebonded or soldered to circuit boards 15, and are electrically connectedto external sources via connections 90 to circuit boards 15. COGs (notshown) may be electrically connected to the edges of the display plates20, which may be electrically connected via ribbon cables to externalsources (not shown). For simplicity, a few exemplary connections 90 areshown in FIG. 2A, although it will be understood that they may beprovided as desired or needed.

The electronic drivers 65 may include VLSI circuits having correspondingexternal leads 80 r and 80 c that are electrically connected throughperimeter seal 25 to row and column electric leads 85 r and 85 c,respectively (see FIG. 2A). Again for simplicity, only a few leads 80from one row TAB 70 r and two column TABs 70 c are shown in FIG. 2A, butit is understood that each row TAB 70 r and each column TAB 70 c mayhave dozens or even hundreds of individual leads 80. The row and columnelectric leads 85 may be distributed throughout an image-generatingmedium, such as liquid crystal material (normally transparent) containedbetween the plates 20, as seen in FIG. 2A.

In addition to holding the plates 20 together, the perimeter seal 25substantially isolates and protects the image-generating medium from theoutside environment. In addition, precisely sized spacers (not shown)may be distributed throughout the image-generating medium. Afterconventional manufacturing, the region between the plates 20 may bemaintained at a partial vacuum to draw the plates 20 against thespacers, e.g., to ensure that the distance between the plates 20 ismaintained at a predetermined cell spacing or “cell gap,” e.g., betweenabout five (5) and six (6) micrometers, which is appropriate for thedisplay 10 to operate normally. Although a COTS AMLCD is described, itwill be appreciated that the tools and methods described herein may beused to customize or otherwise modify other electronic displays, such aspassive matrix LCDs, plasma panels, organic LEDs, and the like.

With reference to FIGS. 1A-2B, an exemplary method will now be describedfor customizing the COTS display 10 of FIGS. 1A and 1B to create thecustomized display 10′ shown in FIGS. 2A and 2B. The COTS display 10 maybe customized in varying degrees, as necessary or desired, and theexamples provided herein are not to be viewed as setting forth requiredtechniques unless specifically so stated.

Initially, a cut line may be identified, such as cut-line 2-2 in FIG.1A, which may separate a target portion 12 of the COTS display 10 (e.g.,corresponding to the portion to be retained to create the customizeddisplay 10′) from an excess portion 14 (e.g., corresponding to theportion that may be discarded or saved for other purposes). In theexample shown, the target portion 12 is substantially square, e.g.,corresponding to a standard shape of a region of an airplane controlpanel (not shown).

Once the cut-line 2-2 is identified, circuit boards 15 may be cut byknown techniques, such as sawing, e.g., along cut-line 2-2.Alternatively, the circuit boards 15 may be removed entirely, e.g., ifnew circuits boards are to be attached to the customized display 10.′ Inaddition or alternatively, TABs 70 may also be cut or removed, e.g.,using similar procedures. If the cut-line 2-2 requires cutting throughan electronic driver 65, the driver may need to be relocated and/orreplaced.

Next, if one or both plates 20 include a polarizer 30 (and/or one ormore other films), at least the portion(s) of the polarizer(s) 30overlying the cut-line 2-2 may be removed. For example, in oneembodiment, the polarizer(s) 30 may be scored, e.g., inside the cut-line2-2, to create a target polarizer portion overlying the target portion,which may be retained during the customization process. The remainder orexcess polarizer portion (e.g., overlying the cut-line 2-2 and theexcess portion 14 of the COTS display 10) may then be removed and/ordiscarded. In another embodiment, the polarizer(s) 30 may be scoredalong two lines on either side of the cut-line 2-2, and the resultingstrip may be removed to provide access to the underlying plate(s) 20.

In still another embodiment, the portion of the polarizer(s) 30immediately overlying the cut-line 2-2 (or offset to either side of thecut-line 2-2, if desired) may be scored or otherwise removed in a singlepass, e.g., by creating a narrow channel or trench through thepolarizer(s) 30 to the surface of the plate(s) 20. For example, toexpose the surface of each of the plates 20, a circular saw blade (notshown) of suitable width, powered by a motor, may be drawn preciselyalong the intended scribe line at a depth substantially equivalent tothe thickness of the polarizer 30 (and/or other films).

Any sawdust, remaining film adhesive, and/or other residue may beremoved, e.g., to clear the exposed surface of the plate 20. Forexample, a vacuum line, a cleaning wheel, a nozzle for a solvent orother liquid, and/or other tool may be directed along the cut-line 2-2to remove any such residue. Such tools may follow the saw blade, e.g.,may be coupled to an arm or other carrier controlling movement of thesaw blade along the plate 20. In addition or alternatively, theresulting channel may be cleaned or otherwise prepared after creatingthe trench, which may facilitate accessing the surface of the plate(s)20 during the subsequent cutting procedure. Exemplary apparatus andmethods for creating such a trench are disclosed in co-pending U.S.application Ser. No. 60/573,421, filed May 21, 2004, entitled “Apparatusand Methods for Cutting Electronic Displays During Resizing,” the entiredisclosure of which is expressly incorporated herein by reference.

Thus, it may be desirable to allow the original polarizer(s) 30 (and/orother films) to remain intact over a target display image area 40′ whilestill providing unobstructed access to the plates 20, e.g., for cuttingor otherwise separating portions of the plates 20 using the proceduresdescribed elsewhere herein. For example, in FIG. 1A, the target displayimage area 40′ of the target portion 12 is defined by a square A-B-C-D,and the polarizer(s) 30 should remain intact at least over this area.The target score line for the polarizer(s) 30 may be the same as line2-2. If so, the resulting trench should be wide enough to allow a scribewheel or other glass-cutting tool (not shown) to reach the surface ofthe plate(s) 20 through the polarizer(s) 30. For example, the trench mayhave a width of not more than about 0.050 inch (1.25 mm), and/or lessthan about 0.030 inch (0.75 mm)

Alternatively, a COTS display 10 may be taken from its originalmanufacturing line before it is completed to simplify resizing. Forexample, the COTS display 10 may be intercepted before the polarizer(s)30 (and/or other films) and/or electronics are attached. Such omitteditems may be added to the customized display (appropriately configuredfor the customized display 10′) after resizing.

Next, the plates 20 of the COTS LCD 10 may be cut, e.g., using aglass-scribing-and-breaking technique, to separate the target and excessportions 12, 14 of the COTS display 10. First, the plates 20 are“scribed,” i.e., a vent is formed along the cut-line 2-2 in each of theplates. For example, with a glazer's wheel (not shown), a vent may becreated successively in each of the plates, e.g., aligned with cut-line2-2 or offset to one side of and parallel to the cut-line 2-2. It isknown that such vents may simply appear as a scratch on the glasssurface, yet may penetrate partially into the plates 20. It will beappreciated that, after scribing the plates 20, the target and excessportions 12, 14 are not separated after the plates 20 are scribed, and,in fact, the interior region of the COTS display 10 may remainsubstantially sealed, e.g., at its original vacuum or other pressure,until the target and excess portions 12, 14 are actually separated fromone another. Alternatively, the target and excess portions 12, 14 mayseparate spontaneously or naturally after being scribed.

The scribe line along each of the plates 20 may be performed in a singlestep or in multiple steps, e.g., using a glazer's wheel, oralternatively by laser scribing, sawing, grinding, etc. Any otherprocedure sufficient to ensure a substantially smooth scribe line inglass (or other materials of the plates 20) may be utilized. Some LCDs,such as AMLCDs, may include plates made from borosilicate hard glass.For such materials, approximately twenty (20) pounds of force has beenshown to be sufficient for scribing the glass using a glass scribingwheel. The scribe wheel may be made of diamond or may be a hard carbidetype wheel, e.g., having a diameter of about three to four millimeters(3-4 mm), and including a sharp angle, e.g., approximately one hundredthirty five degrees (135°)).

To facilitate scribing the plates 20 the COTS display 10, the COTSdisplay 10 may be mounted in a vacuum chuck or other tool (not shown),e.g., to stabilize the COTS display 10. Exemplary tools that may be usedto scribe the plates 20 may include those manufactured by VillaPrecision International of Phoenix, Ariz.. The tool may include aprocessor (also not shown) for precisely controlling components of thetool, e.g., in orthogonal x, y, and z directions. For example, theprocessor may direct the glazer's wheel along the surface of the plates20 in a desired path while maintaining the desired degree ofpressure/force against the plates 20. Optionally, the tool may rotatethe COTS display 10 within the plane of the plates 20, e.g., if a curvedscribe line is desired. Thus, the tool may control the saw, cleaningwheel, and/or scribe in a preprogrammed sequence while maintainingsufficient precision and pressures to remove the film, clean thechannel, and scribe the glass along the desired cut-line 2-2, e.g. usinga single or multiple tool heads.

Next, the plates 20 may be broken to separate the target portion 12 fromthe excess portion 14. It is not customary in the display industry tobreak the display across an internal seal line. However, the plates 20may broken along one or more scribe lines that extend through one ormore internal seal lines using methods similar to those used to cutglass plates without such seal lines. The internal seal line(s) mayprovide some additional resistance to separate the two portions 12, 14,and therefore may require additional displacement of the portions 12, 14relative to one another.

Optionally, to finish cutting the COTS display 10, the COTS display 10may be transferred from the vacuum chuck or other scribing tool (if usedto scribe the plates 20 of the COTS display 10) to a pressure plate tool110. Alternatively, appropriate tools may be included on the scribingtool for accomplishing the cutting.

For example, using the pressure plate tool 110 of FIGS. 3 and 4A-4 c,the plates 20 of the COTS display 10 may be broken along the scribedline(s) while substantially maintaining the spacing of the plates 20,e.g., of the target portion 12. In addition, the pressure plate tool 110may be used to degas the COTS display 10 and/or reseal any exposed edgesof the COTS display 10, e.g., of the target portion 12, as describedfurther below. Generally, the pressure plate tool 110 includes a pair ofpressure plates 116, 118 or other fixture (not shown) and a pressurechamber 114. The pair of pressure plates may include a first plate 116,which may be mounted to a base 120, and a second plate 118, which may bemounted to the first plate 116.

In the embodiment shown in FIGS. 4A and 4B, the first pressure plate 116is pivotally mounted to the base 120 such that the first plate 116 maybe moved between a transverse, e.g., substantially horizontal,orientation (shown in FIG. 4A) and an upright, or substantiallyvertical, orientation (shown in FIG. 4B). Alternatively, the first plate116 may be removable from the base 120 or may be fixed, e.g., in thevertical orientation.

With additional reference to FIGS. 5A and 5B, the first plate 116 mayinclude an inner surface 116 a including one or more apertures 122therein communicating with a port 124. The port 124 may be coupled to afirst vacuum source (not shown), e.g., via one or more sections oftubing 112 (shown in FIG. 4B, e.g., coupled to ports 121 in the base120). After a display, e.g., the COTS display 10, is placed against theinner surface 116 a of the first plate, the first vacuum source may beactivated, and the resulting vacuum may secure the target portion 12against the inner surface 116. The apertures 122 may be provided in apredetermined arrangement, e.g., a plurality of concentric channels 122a, as shown in FIG. 5A. It will be appreciated that other arrangements,similar to known vacuum chucks (not shown), may be provided. Optionally,the first pressure plate 116 may also be used as a vacuum chuck, e.g.,in the transverse orientation, to stabilize the COTS display 10 while ascribing wheel is directed along the exposed plate 20, similar to theprocedures described above.

Returning to FIGS. 3 and 4A-4C, the second pressure plate 118 mayinclude an inner surface 118 a against which a bladder 126 is secured orotherwise disposed. The second pressure plate 118 may include one ormore apertures 128 (one shown in FIG. 3 for illustration only) withinthe interior of the bladder 1226 that communicate with a port 130. Theport 130 may communicate with a pump, a compressed gas container, orother source of inflation media (not shown), e.g., via tubing 112connected to ports 131 in the base 120, thereby allowing inflationmedia, e.g., air, gas, oil, water, and the like, to be delivered into aninterior of the bladder 126 to expand the bladder 126. The bladder 126may be formed from an elastic material or a substantially inelasticmaterial, e.g., transparent silicone rubber, having a thickness of about0.80 millimeter ( 1/32 inch). The bladder 126 may be provided as a sheetwhose edges are secured around the inner surface 118 a of the secondplate, e.g., using an adhesive, fasteners, and/or a tongue and groove orother mechanical interference fit (not shown). Alternatively, thebladder 126 may be a balloon or other enclosed member, e.g., with one ormore ports, that may be bonded or otherwise attached to the innersurface 118 a.

With reference to FIG. 4C, the tool 110 may also include a cover 132that may be placed over the pressure plates 116, 118 to define thepressure chamber 114. For example, the cover 132 may contact the base120 to substantially isolate the pressure chamber 114 from thesurrounding environment. One or both of the cover 132 and base 120 mayinclude one or more seals (not shown) for enhancing a seal between thebase 120 and cover 132 to substantially seal the pressure chamber 114.The base 120 may include one or more apertures 134 therein communicatingwith the pressure chamber 114 and with a port 136 in the base 120. Theport 136 may be connected to a second vacuum source (not shown), e.g.,via tubing (not shown), which may be the same or different source thanthe first vacuum source, for evacuating air from the pressure chamber114, e.g., to expose the target portion 12 of the COTS display 10 to avacuum, as described further below. Optionally, one or more of the firstand second vacuum sources and the source of inflation media may includea release valve 140 (two shown in FIG. 4B) for exposing the respectiveports 121, 131 to ambient pressures.

Returning to FIGS. 3 and 4A-4C, the tool 110 may be used to facilitatebreaking and/or resealing a display, e.g., the COTS display 10.Initially, as shown in FIG. 4A, with the first pressure plate 116 in thetransverse orientation, the target portion 12 of the COTS display 10 maybe placed on the inner surface 116 a of the first pressure plate 116. Asshown in FIGS. 4A, 5A, and 5B, the first pressure plate 116 may includeone or more alignment pins 138 extending from the inner surface 116 afor placing the target portion 12 in a predetermined orientation on theinner surface 116 a. The pins 138 may ensure that the COTS display 10 issecured with the excess portion 14 of the COTS display 10 disposed abovean upper edge 117 of the first pressure plate 116, preferably with thescribe line(s) aligned along the upper edge 117. Optionally, thealignment pins 138 may be movable between different pin holes in theinner surface 116 a, e.g., that correspond to different predeterminedsized displays. In addition or alternatively, one or more of the pins138 may be received in corresponding pockets (not shown) in the secondpressure plate 118, e.g., to facilitate aligning the first and secondpressure plates 116, 118 when they are assembled together.

Once the COTS display 10 is placed against the inner surface 116 a, thevacuum source may be activated to substantially secure the targetportion 12 against the first pressure plate 116. With the first pressureplate 116 in its transverse orientation, the second pressure plate 118may then be mounted to the first pressure plate 116, e.g., using one ormore bolts or other fasteners 127. Thus, the COTS display 10 may bestabilized or otherwise maintained between the pressure plates 18. Inone embodiment, the fasteners or alignment pins 138 may fix the secondpressure plate 118 spaced apart from the first plate 116 by apredetermined distance, e.g., about five millimeters (0.200 inch)

The bladder 126 may then be inflated using the source of inflation mediato a first predetermined pressure, between about one and three poundsper square inch (1-3 psi). The first predetermined pressure may besufficient to maintain the plates 20 of the COTS display 10 at apredetermined spacing. For example, the first predetermined pressure maymaintain the plates 20 of the COTS display 10 at the desired cellspacing for the COTS display 10 to operate normally, as described above.Stated differently, the first predetermined pressure may be sufficientto hold the plates 20 against the internal spacers (not shown) of theCOTS display 10 without improperly compressing or otherwise damaging thespacers. Thus, the first predetermined pressure may prevent the plates20 from moving away from one another, e.g., once the excess portion 14is separated from the target portion 12, and the interior region of thetarget portion 12 is exposed to ambient pressure. If the plates havealready been separated (as described below), the pressure from thebladder 126 may return the plates 20 to their original operationalspacing. The bladder 126 may distribute the pressure substantiallyuniformly over the surface of the target portion 12 of the COTS display10, e.g., to ensure that the spacing between the plates 20 remainssubstantially uniform over the area of the target portion 12.

The excess portion 14 of the COTS display 10 may protrude above theupper edges 117, 119 of the pressure plates 116, 118, e.g., to allow theexcess portion 14 to be broken off from the target portion 12. Theexcess portion 14 may be bent to cause the plates 20 to break along thescribe lines created along the cut-line 2-2, as is known in the industryfor breaking glass. For example, a torque or other substantially uniformforce may be applied, e.g., manually, to the excess portion 14substantially perpendicular to the plane of the plates 20 to break theplates 20.

Optionally, one or both of the upper edges 117, 119 of the pressureplates 166, 118 may include a breaker bar (not shown) to clamp the COTSdisplay 10 immediately adjacent the scribe line(s). The breaker bar(s)may be used to clamp and hold the COTS display 10 below the scribeline(s), to provide a fulcrum for breaking off the excess portion 14 ofthe COTS display 10 and to maintain the cell spacing along the exposededge of the target portion 12 after breaking the COTS display 10 intotwo portions. The breaker bars may be held in place with screws, bolts,and/or other fasteners (not shown), e.g., that may be adjustable inslots (also not shown) in the pressure plates 116, 118. Optionally, anyalignment and assembly, e.g., of the pressure plates 116, 118 and/orbreaker bars may be completed with the first pressure plate 116 in thehorizontal orientation, shown in FIG. 4A. If the two portions 12, 14have already been separated, the breaker bars may be unnecessary.

After assembly, pressurization, and/or and cleaning, the pressure plates116, 118 may be moved to the vertical orientation, as shown in FIG. 5B,thereby orienting the excess portion 14 up, which may facilitatebreaking and resealing, as described below. Thus, the excess portion 14of the COTS display 10 may protrude from the pressure plates 116, 118,with the scribe line(s) precisely aligned with the upper edges 117, 119and/or with the edge(s) of the breaker bar(s). For example, the scribeline(s) may be set about 0.50-1.25 millimeters (0.020 to 0.050 inch)above the upper edges 117, 119 of the pressure plates 116, 118 and/orthe breaker bars. The excess portion 14 may be torqued a small angle,causing each of the plates 20 of the COTS display 10 to fracture alongthe scribe line(s), e.g., simultaneously or sequentially, therebybreaking and separating the excess portion 14 from the target portion 12that remains between the pressure plates 116, 118.

With the excess portion 14 separated, the interior region of the targetportion 12 is exposed to atmospheric pressure, which may besubstantially higher than the original pressure within the interiorregion of the target portion 12. Because the target portion 12 isstabilized between the pressure plates 116, 118, e.g., using the bladder126, the plates 20 remain substantially at the predetermined cellspacing. Without the pressure plates 116, 118, the tendency of theplates 20 would be to separate as air is drawn therebetween, which mayimpair or destroy the effectiveness of the target portion 12 to displayimages. Because of the pressure plates 116, 118, the plates 20 remainpositioned against the spacers within the interior region to preservethe predetermined cell spacing.

With the excess portion 14 removed, the target portion 12 now has anexposed edge 16. As shown in FIGS. 4B and 4C, one or more seals may thenbe applied along the exposed edge 16 to substantially seal the interiorregion of the target portion 12 and/or ruggedize the target portion 12to create the customized display 10.′ For example, a first seal 26 maybe applied along the exposed edge and preferably between the plates 20.

In one embodiment, to apply the first seal 26 between the plates 20, thebladder 126 may be expanded, e.g., by introducing additional inflationmedia therein, to squeeze the plates 20 towards one another. In anexemplary embodiment, the bladder 126 may be expanded to a secondpredetermined pressure greater than the first predetermined pressure,e.g., by increasing the pressure between about one and two pounds persquare inch (1-2 psi). The second predetermined pressure may result inthe spacers within the interior region being compressed slightly, butwithout causing any permanent deformation or damage. In an alternativeembodiment, it may be unnecessary to reduce the pressure to eject liquidcrystal from between the plates 20. In this alternative, a low viscosityadhesive may sufficiently penetrate between the plates 20 givensufficient time, e.g., if the plates 20 are maintained in the verticalorientation shown in FIGS. 4B and 4C. Although this may increase thedistance between the plates 20 (as the adhesive flows between the plates20), the percentage of volume increase within the region between theplates 20 may be sufficiently low that the performance of the customizeddisplay may not be substantially affected. Alternatively, the adhesivemay displace at least a portion of the LC material and/or maysufficiently mix with the LC material along the exposed edge to create aseal. In addition or alternatively, adhesive may be forced into theregion between the plates 20, e.g., by manually or mechanically pressingagainst the exposed edge 16 after applying the adhesive, e.g., with atool, dispenser, or even a finger or thumb, to press the adhesive inbetween the plates 20 (either with or without creating a space betweenthe plates 20 to receive the adhesive).

As the plates 20 are squeezed, the volume of the interior region isreduced, thereby causing at least some of the liquid-crystal materialtherein to be ejected along the exposed edge 16 from between the plates20 (since the liquid-crystal material is incompressible). The excessliquid-crystal material that has escaped along the exposed edge 16 maythen be removed, e.g., by wiping, wicking, draining, and the like, e.g.,with a cloth, paper, cotton swab, compressed air, and the like (notshown). If desired, the exposed edge 16 may also be cleaned or otherwiseprepared in addition to removing the excess liquid-crystal material.

An adhesive, e.g., a bead of flowable adhesive, may then be appliedalong the exposed edge 16 to seal the target portion 12, e.g., while thetarget portion 12 is held in the vertical position. The adhesive mayhave an appropriate viscosity, e.g., to allow it to flow inwardlybetween the plates 20, and/or to fill any empty space in the targetportion 12 between the plates 20 and the liquid crystal materialremaining between the plates 20, as described further below. A wettingand/or thinning agent may be used, if it is desirable to reduce theviscosity of the adhesive. Commercially available UV curing acrylicswith nominal viscosity have been found to be appropriate. Otheradhesives, such as epoxies and urethanes, may also be suitable for useas the first seal.

The adhesive and/or target portion 12 may need to be outgassed, e.g., toremove any trapped gases and/or voids before the adhesive is cured. Withreference to FIG. 4C, both the outgassing and the curing may beaccomplished using the pressure plate tool 110 or other tool. As shown,the cover 132 may be placed over the base 120 to substantially isolatethe pressure chamber 114, and consequently the target portion 12, fromthe surrounding environment. The second vacuum source may be reduced toa pressure sufficient to remove trapped gases from the adhesive and/orthe interior region of the target portion 12, e.g., below about onepound per square inch (1 psi) absolute. The gases may be observed asbubbles at the top of the adhesive layer. When the bubbles stopaccumulating on the surface of the adhesive, the degassing may beconsidered substantially completed.

Once sufficient degassing has been completed, the pressure chamber 114may be brought back to atmospheric pressure, e.g., by deactivating thesecond vacuum source and/or opening a release valve to expose thepressure chamber 114 to ambient pressure. Optionally, the cover 132 maybe removed or may remain over the base 120. Alternatively, the pressurechamber 114 may remain at the second predetermined pressure during thesubsequent steps.

The pressure in the bladder 126 may then be reduced to a thirdpredetermined pressure to draw the adhesive into the exposed edge 16between the plates 20. As the pressure in the bladder 126 is reduced,the plates 20 may separate, thereby increasing the volume of theinterior region, and drawing at least some of the adhesive between theplates 20 (to preserve the volume of material within the interiorregion). In an exemplary embodiment, the third predetermined pressuremay be the same as the first predetermined pressure, such that theplates 20 are returned to the original predetermined cell spacing. Thus,the volume of adhesive drawn between the plates 20 may be substantiallythe same as the volume of liquid-crystal material that is ejected frombetween the plates 20. In addition or alternatively, the pressure withinthe chamber 114 may also be increased slightly, e.g., to force adhesivealong the exposed edge 16 between the plates 20 or otherwise enhancepenetration of the adhesive, if desired.

After the adhesive has penetrated between the plates 20, the adhesivemay be cured by appropriate methods to complete resizing the customizeddisplay 10.′ For example, for a UV-curable adhesive, the target portion12 may be exposed to ultraviolet light for sufficient time tosubstantially cure the adhesive between the plates, e.g., for at leastabout thirty seconds to two minutes depending upon the intensity of theUV and the sensitivity of the adhesive. Optionally, a UV curing lamp(s)and/or heater(s) (not shown) may be mounted in the pressure chamber 114of the pressure plate tool 110 to facilitate curing. Alternatively,other adhesives may be utilized that are cured using heat and/orpressure.

Optionally, any excess adhesive disposed along the exposed edge 16 maybe removed, e.g., wiped away before the adhesive is cured, or cut,scraped away, or otherwise removed, e.g., using chemicals or mechanicaldevices, after the adhesive is cured. Alternatively, the excess adhesivemay remain along the sealed exposed edge 16. For example, an excessamount of adhesive may be added to the display 10′ to be used duringsubsequent assembly or other preparation of the final product. Suchexcess adhesive material may be contoured and shaped, e.g., by moldingand the like, to facilitate interfacing with a bezel (not shown) and/orotherwise optimize the display design.

After curing, the customized display 10′ is removed from the pressureplate tool 110, and cleaned as necessary and/or tested. Optionally, oneor more additional seals may be added to the customized display 10,′along the now-sealed exposed edge 16 and/or along one or more of theadditional edges. For example, a second seal 27 may be added, asdesired, and then outgassed and/or cured as necessary. The second seal27 may be a silicone or other material, e.g., applied to minimize thepenetration of humidity and/or other contaminants into the liquidcrystal material inside the cell, e.g., when the display 10′ subjectedto its operating environment. Optionally, the second seal 27 may haveblack ink, dye, and/or other pigment added thereto to produce asubstantially black or other opaque color, and may be applied up to theouter perimeter of the target display image area 40′, to prevent backlight from passing through the display 10′ around the outer edges of thetarget display image area 40.′

In addition or alternatively, an optional mask or third seal 28 may beadded to the newly-exposed plate edges, e.g., over the seal 27, and/orapplied up to the outer perimeter of the target display image area 40.′The mask 28 is shown partially broken away in FIG. 2A. It should bedark, e.g., black, and may be tape, ink, sealant, adhesive, plastic,and/or any other suitable material. At least one of the second seal 27,or the optional mask 28 may be used to replace any of the original mask(not shown) removed during the customization process. Additionally, themask 28 may be placed around the entire perimeter of the cell, e.g.,substantially overlying the original perimeter seal 25 and originalmask. The third seal or mask may cover part of the active area of thecustomized display 10′ that is not used or desired to be seen be theuser in the final implementation. Methods for applying such secondand/or third seals 27, 28 are described in U.S. Pat. No. 6,204,906, theentire disclosure of which is expressly incorporated herein byreference.

Alternatively, the first seal 26 may serve the functions of the secondand/or third seals just described. In addition or alternatively, one ormore of the seals may be loaded with thermally conductive material,e.g., to aid in thermal conduction, and/or electrically conductingmaterial, e.g., to aid in EMI shielding and/or grounding.

If any of the electronics, e.g., internal or external to the customizeddisplay 10,′ are cut, damaged, and/or removed, electrical continuity mayneed to be reestablished. Optionally, new circuits may be needed toreplace those cut, damaged, and/or removed, or to enhance thefunctionality of the customized display 10.′ Methods for repairing orreplacing such circuits are described in U.S. Pat. No. 6,204,906,incorporated by reference above. Optionally, other cuts may be performedand/or sections of a COTS display may be removed, e.g., using theexemplary methods described in U.S. Pat. No. 6,204,906.

Turning to FIG. 6, an exemplary method is shown for resizing,customizing, or otherwise modifying an electronic display, such as aCOTS AMLCD and the like. Although the steps are provided in a sequentialorder, it will be appreciated that the order in which the steps areperformed may be varied. Further, one or more of the steps may beeliminated and/or may be substituted with one or more of the steps fromother methods described herein.

First, at step 210, the display may be removed from its frame assembly,e.g., if a fully assembled display apparatus is being resized. This mayinclude removing any excess electronics that may interfere with aportion of the resizing procedure, and/or that may be modified orreplaced with other electronics.

At step 212, one or more circuit boards of the display may be cut, e.g.,using hand or power tools, such as a hand shear. Optionally, any cutedges may trimmed or otherwise treated, e.g., using a mill, router,sandpaper, and the like.

At step 214, one or more polarizers and/or other films may be removedfrom at least a portion of the display, e.g., on the exposed surfaces ofone or both plates of the display. For example, any films along the lineto be scribed may be cut or otherwise removed, e.g., using a smallelectric circular saw. The saw may be mounted to a machine toolassembly, e.g., along with a milling machine, grinding machine, and/orother tools used during the resizing procedure.

Optionally, the display may be mounted on a vacuum chuck located at themachine tool assembly, and/or on a movable bed of the machine toolassembly. The machine tool assembly may be used to hold the displayprecisely and/or move it under the saw. Control of the machine tool,e.g., along X, Y and Z axes, may be used to control the motion of thevacuum chuck holding the display under the saw blade and/or other tools,similar to the previous embodiments.

This step may include removing a swath of the polarizer and/or otherfilms to create a trench having a width, e.g., about 1.25 millimeters(0.050 inch) or less, centered over the intended cut line. Any sawdustor other residue from the films created from the sawing action may beremoved using a vacuum cleaner, e.g., appropriately positioned on thesaw and/or machine tool assembly. The film adhesive may be cleaned alongthe trench, e.g., using a cotton swab, fabric, sponge, and the like,alone or along with a solvent, such as 91% isopropyl alcohol solution.This procedure may be repeated on both sides of the display ifpolarizers or other films are provided on both sides. Alternatively,another procedure may be used for removing at least a portion (andoptionally all) of the polarizer(s) on the plate(s) of the display. Inyet another alternative, the display may not include any polarizers orfilms (e.g., as explained above), and this step may be omitted.

At step 216, one or both plates of the display may be scribed along theintended cut line(s). In one embodiment, the plates may be scribed witha glazer's scribe wheel along the intended cut line. The parameters forscribing using a scribe wheel, i.e., scribing speed and pressure, aresimilar to those used in the LCD industry for scribing glass plates ofLCDs. The saw blade for cutting the polarizer(s) and the scribe wheelmay be mounted on the same tool head, e.g., such that the cutting andscribing steps may be completed successively in one pass along eachplate of the display. For example, the scribe wheel and/or saw may belowered successively when used, e.g., using a pneumatic, hydraulic,mechanical, or other actuators that control the positions of the toolsalong the Z axis.

At step 218, the display may be broken along the scribe line(s). Forexample, the display may be removed from the vacuum chuck or other tool,and placed on a flat glass plate. A strip of material, e.g., a 0.008inch thick silicone or rubber strip, may be placed on the flat platebefore the display such that the rubber strip is substantially parallelto the scribe line offset to one side, e.g., about fifty (50)millimeters (two (2) inches) away from the scribe line. The scribe lineof the upper plate may then be stroked with a cotton swab or other toolat moderate pressure, e.g., to cause the lower plate of the display tobreak along the scribe line. The display may be turned over, placed uponthe flat plate over the rubber strip and aligned in a similar manner,and the other plate (now exposed) may be stroked in a similar manner, tobreak the (now) lower plate along the scribe line. Thus, the display maybe separated into multiple pieces, e.g., into a target portion and anexcess portion.

If the plates are not broken after a single pass, these steps may berepeated, as necessary, on one or both sides of the display, until thedisplay is separated. Generally, only one side of the display will breakalong the scribe line at a time (i.e., the lower plate opposite theupper plate being stroked). However, during some procedures, both sidesmay break simultaneously along the scribe lines. In addition, one orboth plates may break spontaneously during the scribing operation,thereby omitted one or both of the stroking steps. Alternatively, therubber strip may be replaced with a continuous sheet of flexiblematerial under the display, and the display may be broken, e.g., using atool that uniformly strikes the display along the scribe line, such asthe tools used by Villa Precision for breaking glass done in the glasscutting industry. In a further alternative, the display may be brokenand/or separated in the pressure plate tool, similar to the otherembodiments described herein.

When the display breaks into the target and excess portions, the platesof the display may expand, e.g., along the exposed edges of the targetand excess portions. As explained above, this may occur because theregion between the plates of the display may be at a reduced pressure,e.g., substantially at a vacuum. When the display is broken or otherwiseseparated along the scribe line(s), atmospheric pressure may enter theregion between the plates, thereby causing the plates to separate orotherwise expand away from one another a distance greater than theperformance spacing. Alternatively, the scribed display may be brokenalong the scribe line(s) while maintaining the plates in their originalperformance spacing, e.g., by mounting the display in a fixture or usingother procedures similar to those described elsewhere herein.

At step 220, the target portion of the display (the portion to be usedfor the resized display) may be placed in a pressure plate tool, e.g.,similar to that described above. For example, the pressure plate toolmay include two substantially rigid, parallel plates, at least one ofwhich is covered with a bladder, such as a flexible silicone rubber andthe like. The bladder may be held in place on one of the pressureplates, e.g., using bars on multiple (e.g., three) sides of the pressureplate. The pressure plates and/or bars may be formed from aluminum orother substantially rigid material capable of handling the pressuresinvolved. In addition, the bladder may include one or more ports, e.g.,on a top side of the bladder for delivering inflation media into thebladder, similar to the previous embodiments.

The display may be placed between the pressure plates with the exposedor cut edge of the target portion protruding slightly from one edge ofthe pressure plate tool, e.g., along top edges of the pressure plates.The pressure plates may be secured together, e.g., using one or morebolts, clips, or other fasteners. The pressure within the bladder mayincreased, e.g., adjusted to approximately two pounds per square inch (2psi) gauge pressure, e.g., to return the distance between the platessubstantially to their original gap distance. As explained above, thismay be facilitated because the display includes internal spacers betweenthe plates of the display, and the pressure may force the plates backagainst the spacers.

At step 222, a small amount of liquid crystal material may be ejected orotherwise removed from between the plates of the display along theexposed edge, e.g., to create a space between the plates for receivingan adhesive or other sealant. For example, the pressure in the bladdermay be increased slightly, e.g., by about one to three psi, to compressthe plates of the display slightly together from their intendedperformance spacing, thereby causing a small amount of LC material to beforced out along the exposed edge. The exposed LC material may beremoved, e.g., using a cotton swab, fabric, or other absorbent ornonabsorbent material. In addition, the exposed edge may be cleanedand/or otherwise treated. Alternatively, the LC material may be removedfrom between the plates, e.g., by wicking, draining, and the like,similar to the embodiments described above.

At step 224, adhesive or other sealant material may be applied along theexposed edge. Optionally, the pressure plate tool (along with the targetportion of the display) may be set in a vertical position to accept theadhesive, similar to the previous embodiments. For example, a UV curingacrylic adhesive may be applied from a dispenser substantially uniformlyalong the exposed edge. Any excess adhesive may be removed, e.g., usinga cotton swab, fabric, and the like.

At step 226, the pressure in the bladder may be reduced, e.g., to aboutone pound per square inch gauge pressure, allowing the adhesive topenetrate and enter between the plates along the exposed edge. For anadhesive such as Loctite 349, it may require several minutes for theadhesive to penetrate sufficiently between the plates. For example, itmay take about four (4) minutes for the adhesive to penetrate a distanceof at least about 0.040 inch in between the plates. The penetrationdistance is generally proportional to the time allowed. The pressure maybe reduced sufficiently to return the plates of the display to theiroriginal performance spacing, similar to the previous embodiments. Atstep 228, the adhesive may then be cured. For example, one or moreultraviolet fluorescent lamps, e.g., rich in energy at about threehundred fifty nanometers (350 nm) wavelength, may be activated for atleast about one minute. In an exemplary embodiment, a set of five lamps,such as Model F8T5BL lamps by Ushio may be sufficient. The adhesive maybe only partially cured such that the display may be removed, and anyexcess adhesive may be cleaned or otherwise removed without permanentattachment to the pressure plate tool or display, e.g., in undesirablelocations. The display and/or pressure plate tool may be cleaned, forexample, with a solvent such as 91% isopropyl alcohol solution. Curingof the adhesive may then be completed by exposing the display to the UVlamps, e.g., for another ten (10) or more minutes.

Thereafter, the display may be cleaned as needed. Optionally,thereafter, additional electronics may be attached to the display and/orthe display may be mounted within a bezel, box, or other assembly,similar to original displays.

While certain embodiments are illustrated in the drawings and aredescribed herein, including preferred embodiments, it will be apparentto those skilled in the art that the specific embodiments describedherein may be modified without departing from the inventive conceptsdescribed.

For example, depending upon the specific requirements for a particularapplication, various combinations of the customizing techniquesdescribed herein may be applied. The seals 26, 27, and 28, may beapplied in different combinations, different amounts or ratios, andvarying sequences, depending on the application. Some of the seals maybe omitted or used redundantly as the application may require. Inaddition or alternatively, degassing may not be necessary in someapplications.

Additionally, though the examples used herein generally referred to COTSAMLCDs as used in avionics where square displays are used, the conceptsare equally applicable to other types of LCDs or other displaytechnologies, and for other industrial applications including thoserequiring other customized shapes. Furthermore, though the examples usedshow only one set of row TABs and two sets of column TABS, in practicethat may be switched, or there may be two sets of each, and the quantityof each may vary, all as is desired or needed for a specificapplication.

While the invention is susceptible to various modifications, andalternative forms, specific examples thereof have been shown in thedrawings and are herein described in detail. It should be understood,however, that the invention is not to be limited to the particularembodiments or methods disclosed, but to the contrary, the invention isto cover all modifications, equivalents and alternatives falling withinthe scope of the appended claims.

1. A method for resizing an electronic display, the display comprising afront plate, a back plate, a perimeter seal spacing the front and backplates apart, and image-generating medium contained in an area betweenthe front and back plates and within the borders of the perimeter seal,the front and back plates being spaced apart by a predetermined cellgap, the method comprising: identifying a target portion and an excessportion of the display; separating the target portion from the excessportion, thereby creating an exposed edge along the target portionextending from one side edge to another side edge of the display andcommunicating with the area between the plates of the target portion;stabilizing the target portion after separation such that the front andback plates are separated by a distance not greater than thepredetermined cell gap; applying adhesive along the exposed edge; andforcing the adhesive into the region between the plates along theexposed edge.
 2. The method of claim 1, wherein the target portion ofthe display is mounted within a fixture for maintaining the plates atthe predetermined cell gap.
 3. The method of claim 2, wherein thefixture presses the plates of the target portion towards one anotherbefore the adhesive is applied along the exposed edge, and returns theplates of the target portion to the predetermined cell gap to force theadhesive into the region between the plates.
 4. The method of claim 2,wherein the fixture comprises a pair of pressure plates between whichthe target portion of the display is mounted.
 5. The method of claim 4,wherein at least one of the pressure plates comprises a bladder disposedbetween the respective one of the pressure plates and the target portionof the display, and wherein the plates of the target portion are pressedtowards one another by expanding the blabber.
 6. The method of claim 4,wherein the plates of the target portion are returned to thepredetermined cell gap by at least partially deflating the bladder. 7.The method of claim 4, wherein the target portion of the display ismounted to a first plate of the pressure plates, and wherein a secondplate of the pressure plates is mounted to the first plate at apredetermined spacing.
 8. The method of claim 1, further comprisingcuring the adhesive, thereby creating a first seal between the platesalong the exposed edge, the first seal creating a barrier to prevent theimage-generating medium from escaping out of the area between the platesof the target portion.
 9. The method of claim 1, whereinimage-generating material is forced out from the area between the platesalong the exposed edge by compressing the plates of the target portiontowards one another, and wherein the plates of the target portion are atleast partially released to force the adhesive between the plates. 10.The method of claim 9, further comprising removing image-generatingmaterial that is forced out along the exposed edge.
 11. The method ofclaim 10, wherein the image-generating medium is removed before theadhesive is applied along the exposed edge.
 12. The method of claim 1,wherein the adhesive is forced into the region between the plates bypressing against the exposed edge after applying the adhesive.
 13. Themethod of claim 12, wherein the adhesive is forced into the regionbetween the plates using a tool.
 14. The method of claim 12, wherein theplates are maintained in a vertical orientation when the adhesive isapplied to the exposed edge.
 15. The method of claim 1, wherein forcingthe adhesive into the region between the plates increases the distancebetween the plates.
 16. The method of claim 1, wherein forcing theadhesive into the region between the plates displaces at least a portionof the image-generating material between the plates.
 17. The method ofclaim 1, wherein forcing the adhesive into the region between the platescauses the adhesive to mix with image-generating material between theplates.
 18. The method of claim 1, wherein the adhesive is forced intothe region between the plates using a dispenser.
 19. The method of claim18, wherein the adhesive is applied from the dispenser substantiallyuniformly along the exposed edge.
 20. A method for resizing anelectronic display, the display comprising a front plate, a back plate,a perimeter seal spacing the front and back plates apart, andimage-generating medium contained in an area between the front and backplates and within the borders of the perimeter seal, the front and backplates being spaced apart by a predetermined cell gap, the methodcomprising: identifying a target portion and an excess portion of thedisplay; separating the target portion from the excess portion, therebycreating an exposed edge that extends from one side edge to another sideedge of the display along the target portion communicating with the areabetween the plates of the target portion; pressing the plates of thetarget portion towards one another; and at least partially releasing theplates of the target portion to draw adhesive between the plates alongthe exposed edge.
 21. A method for resizing an electronic display, thedisplay comprising a front plate, a back plate, a perimeter seal spacingthe front and back plates apart, and image-generating medium containedin an area between the front and back plates and within the borders ofthe perimeter seal, the front and back plates being spaced apart by apredetermined cell gap, the method comprising: identifying a targetportion and an excess portion of the display; separating the targetportion from the excess portion, thereby creating an exposed edge alongthe target portion communicating with the area between the plates of thetarget portion; applying adhesive along the exposed edge; and forcingthe adhesive into the region between the plates along the exposed edge,thereby displacing at least a portion of the image-generating materialbetween the plates.
 22. The method of claim 21, wherein the adhesive isforced into the region between the plates using a tool or dispenser. 23.The method of claim 21, wherein forcing the adhesive into the regionbetween the plates causes the adhesive to mix with image-generatingmaterial between the plates.
 24. The method of claim 21, wherein forcingthe adhesive into the region between the plates increases the cell gapbetween the plates.